Lightweight Gear Assembly

Overview

Teeth that mesh first try

The brief called for a driver and driven gear with lightening pockets — geometry no hob could cut in one setup. SLS nylon gave stiff, wear-tolerant teeth straight off the build.

We nested the pair with witness coupons, cleared every pocket of powder and checked tooth profiles against the client's datum scheme before dispatch.

Challenge & Approach

Light gears, true profiles

• Profile offset tuned so the printed pair meshes without binding.
• Pocketed hubs cut rotating mass while keeping the rim stiff.
• First-article report on bore fit and backlash before batch release.